Method and apparatus for auto-cascade bottle filling

ABSTRACT

A system is disclosed for filling bottles and other fluid holding vessels. In the system, a pressure transducer monitors fluid pressure within a conduit that communicates with fluid filled storage banks. Using a programmable logic controller, valves associated with the banks may be systematically opened to cause fluid to pass though the conduit and into a downstream bottle. As a particular bank has discharged and the downstream bottle is filled the rate of change in the pressure in the conduit will fall to zero. If the bottle has been filled before or upon equalization of the pressure, the fill operation may be discontinued. However, if the bottle is not filled, the controller may then cause the valve to close, and the either activate a compressor or open the valve of a second bank causing that bank to discharge into the conduit and continue filling the bottle.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority from U.S. Provisional Patent Application No. 61/088,846, filed Aug. 14, 2000.

FIELD OF THE INVENTION

Disclosed is an embodiment for an auto-cascade bottle filling system that may improve overall filling efficiency and reduce or eliminate operator fatigue. The system may include a programmable logic controller that may communicate with a pressure transducer and function to actuate valve(s) associated with a fluid storage bank(s) to allow for the rapid, controlled, and automated filling of bottles.

BACKGROUND OF THE INVENTION

Methods of filling bottles with fluid (including compressed air, compressed breathable air, compressed natural gas and the like, and liquids) have used either a manually controlled valve or a spring biased differential pressure valve to control the flow of fluid from a fluid reservoir into a bottle. Manual valves permitted increased operator control and allowed for greater efficiency in equalizing the pressure between the reservoir and the target bottle. A disadvantage, however, of a manual valve was the significant user fatigue inherent with its use. Therefore, as an alternative to a manual valve, some systems used a spring biased pressure differential valve. These valves reduced operator fatigue, but were less efficient than manual valves since the inherent bias of a spring would terminate fluid flow from the reservoir prior to the equalization of pressure between the fluid reservoir and the target bottle.

Accordingly, it would be advantageous to have an automatic filling system that may reduce operator fatigue and increase the efficiency with which a target bottle may be filled relative to the fluid reservoir.

SUMMARY OF THE INVENTION

An apparatus and method is disclosed for auto-cascade bottle filling. The apparatus may include a fluid conduit, one or more valves that communicate with the conduit, a pressure measuring device and a programmable logic controller. The fluid conduit may communicate with a downstream vessel filling station or port. The pressure measuring device may be arranged to measure the rate of change of a fluid pressure in the conduit. The programmable logic controller communicates electronically with the pressure measuring device and may transmit control signals to the valve(s).

One or more fluid filled (or fillable) storage balks may also be provided, with each of the banks communicating with the valve(s) so that the bank(s) may be selectively discharged by operation of the respective valve.

In operation, a bottle or other fluid retaining vessel or container to be filled may be oriented at the filling station or port so that the bottle interior is in communication with the fluid conduit. Then, upon initiation of a fill operation by a user, the programmable logic controller may cause a valve associated with a bank to open so that fluid in the bank discharges through the conduit and into the bottle. As the bottle is filled, and the pressures at the bottle and the bank equalize, the rate of change in the pressure in the conduit will approach zero. If the rate of change reaches zero (or another value predetermined by a user) and the bottle has not been fully charge, the programmable logic controller may continue the filling operation by signaling the open valve to close and a second valve associated with another bank to open.

It will be appreciated that a regulator on, for example, at least one of the bottle, the station, or the port, may serve to limit fluid pressure in the bottle. Accordingly, where the bottle has been filled (i.e., full charged to a desired PSI), the regulator may prevent additional fluid flow into the bottle. As a result, fluid pressure in the conduit may quickly rise and equalize. This rapid equalization of the pressure in the conduit may be sensed by the pressure measuring device and, as mentioned supra, cause the programmable logic controller to close the open valve. In addition, the controller may then terminate the fill operation by cycling through any remaining banks/valves, which would be rapidly opened and closed given the high pressure resident in the conduit at the end of the fill operation.

The disclosed apparatus and method may further include a fluid compressor that may be arranged to fill the banks. The compressor may also be arranged so that it communicates directly with the fluid conduit. In such an arrangement, the compressor may be used to directly fill a bottle at the fill station or port in the event, for example, all banks have been discharged and all bottles have not been filled.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will be herein to the associated drawings, wherein like reference numbers refer to like part throughout, and wherein:

FIG. 1 is a perspective view of an embodiment of a fill apparatus for a fluid holding vessel;

FIG. 2 is a diagrammatic view of an embodiment of a fill apparatus for a fluid holding vessel;

FIG. 3 is a flowchart view of an embodiment of a method for filling a fluid holding vessel.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A fill apparatus for a fluid holding vessels may include a fluid conduit, one or more valves, a pressure measuring device and a programmable logic controller. The valve(s) may communicate with the fluid conduit and the pressure measuring device and operate to measure a rate of change of a fluid pressure in the conduit. The programmable logic controller may be in electronic communication with the valve(s) and the pressure measuring device, and operate to transmit a control signal to the valve (or a predetermined valve in a plurality of valves or a combination of valves) in response to a predetermined rate of change in the fluid pressure in the fluid conduit.

Referring now to FIGS. 1 and 2, an apparatus 10 for filling a fluid holding vessel 100 may include a common outlet line or fluid conduit 12 and one or more valves 14 (i.e., a first valve, second valve, third valve, etc.) that may communicate (i.e., to be linked or connected by tubes, conduits or the like that allow the transmission of a fluid) with the fluid conduit 12. A pressure measuring device 16 may be provided that may operate to measure a rate of change of a fluid pressure in the fluid conduit 12. A programmable logic controller 18 may also be included that may communicate electronically (via wire or wirelessly) with the valve(s) 14 and the pressure measuring device 16, and operate to transmit a control signal to the valve(s) 14 in response to a predetermined rate of change in the fluid pressure in the fluid conduit 12 as measured by the pressure measuring device 16.

Still referring to FIGS. 1 and 2, one or more fluid filled (or fillable) storage banks 20 may be provided that may communicate with the fluid conduit 12 through respective outlet lines 22. The banks 20 may be most any fluid retaining container, including bottles, tanks, cylinders, drums, etc. A valve 14 may be connected to and communicate with the outlet line 22 of each storage bank 20. Further, as will be described infra, each valve 14 may be selectively actuated to control the discharge of a fluid (not shown) from a predetermined storage bank(s) 20, into and through the fluid conduit 12, and into a downstream vessel 100, vessel filling station 102 or port, or another apparatus that may have use for the fluid and that may be communicate with the discharge end 24 of the conduit 12. As such, it will be appreciated that the specific position of the valve(s) 14 may be somewhat flexible, in that each valve(s) 14 may be mounted directly to a bank 20, positioned in the outlet line 22 of a bank 20, remote from the bank 20 or the conduit 12, or mounted directly on the conduit 12. A housing 26 and/or manifold and other mounting and/or reinforcing apparatus may also be provided for mounting of the valve(s) 14 and conduit 12 and to otherwise meet the needs of a user. Additionally, where the fluid to be transmitted is compressed natural gas, the housing 26 (and other features such as the banks 20) may be constructed to be explosion proof and/or resistant.

Still referring to FIGS. 1 and 2, a fluid (such as compressed air, compressed breathable air, compressed natural gas and the like) may be provided to the storage banks 20 by a fluid compressor 28 that may communicate with the inlet 29 of each the bank 20 through a second fluid conduit 30 or common input line. The operation of the compressor 28 and the filling of the one or more storage banks 20 may be controlled by the programmable logic controller 18, which may be in electronic communication (wire or wireless) with the compressor.

Still referring to FIGS. 1-3, in operation, after a vessel 100 (e.g., a bottle, tank, container, cylinder or other fluid storage receptacle) has been connected to a bottle filling station 102 or port (and/or otherwise placed in communication with the discharge end 24 of the conduit 12), a user may then initiate a fill operation (by, for example, depressing an associated on-off switch (not shown) or the like that may communicate with the programmable logic controller 18). Once initiated, tie programmable logic controller 18 may signal a valve 14 of a predetermined one of the storage banks 12 to open and cause fluid to flow from the storage bank 20 and through the conduit 12 and to the discharge end 24.

Still referring to FIGS. 1-3, as mentioned supra, the pressure measuring device 16, which may be a pressure transducer, may monitor the fluid pressure in the conduit 12. As the vessel 100 is filled, and the pressures at the vessel 100 and the bank 20 equalize, the rate of change in the pressure in the conduit 12 will approach zero. If the rate of change reaches zero (or another value as predetermined by the user) and the vessel 100 has not been fully charged, the programmable logic controller 18 may then continue the filling operation by signaling the open valve 14 to close and signaling a second valve 14 associated with another bank 20 to open. This process of discharging fluid from each bank 20 to the point of pressure equalization (or other predetermined value), and then switching to the next storage bank 20 may continue as needed for the vessel filling process until all vessels 100 are filled.

It will also be appreciated that a pressure regulator (not shown) on, for example, at least one of the vessel 100, or the vessel filling station 102 or the port, may serve to limit fluid pressure in the vessel 100. Accordingly, where the vessel 100 has been filled (i.e., full charged), the regulator may prevent additional fluid flow into the vessel 100. As a result, fluid pressure in the conduit 12 may quickly rise and equalize. This rapid equalization of the pressure in the conduit may be sensed by the pressure measuring device 16 and, as mentioned supra, cause the programmable logic controller 18 to close the currently opened valve 14. In addition, the controller 18 may then terminate the fill operation by cycling through any remaining banks 20 valves 14, which would be rapidly opened and closed given the high pressure resident in the conduit 12 at the end of the fill operation.

Still referring to FIGS. 1-3, the compressor 28 may communicate with the conduit 12 so that vessels 100 may also be directly filled by the compressor 28. For example, in the event all vessels 100 have not been filled after all the available storage banks 20 have been discharge, the compressor 28 may continue to directly fill bottles using a branch line 34 or conduit that extends from the second conduit or common inlet line 30 to the fluid conduit 12.

Still referring to FIGS. 1-3, in addition to the valve(s) 14 associated with each storage bank(s) 20, which may be solenoid controlled, a control valve 32 (that may also be solenoid controlled) may be positioned in the common input line 30 (or at an inlet thereof). This additional control valve 32 may control the filling of the storage banks 20 and, when closed, cause fluid to instead flow directly from the compressor 28 to the conduit 12. For example, if as mention above a user desired to use the compressor 28 to supply fluid to another piece of equipment, the operator may close the valve 32 in the inlet line 30 so that the flow of fluid to the storage banks 20 will cease and fluid may instead be transmitted to the conduit 12 and the discharge end 24 thereof. In will, of course, be appreciated that a check valve (not shown) may also be positioned at the compressor 28, in the line 34, or in the conduit as some intermediate point therebetween, to prevent backflow of a fluid from the conduit 12 to the compressor 28.

Having thus described an embodiment of the system 10, various other embodiments will become apparent to those of skill in the art that do not depart from the scope of the appended claim. 

1. A fill apparatus for a fluid holding vessels comprising: a first and a second fluid storage bank, each bank communicating with a common outlet line; a first valve operable to selectively control the flow of a fluid from the first storage bank into the common outlet line; a second valve operable to selectively control the flow of a fluid from the second storage bank into the common outlet line; a pressure measuring device operable to measure a rate of change of a fluid pressure in the common outlet line; and a programmable logic controller in electronic communication with the first and second valve and the pressure measuring device and operating to transmit a control signal to at least one of the first or second valves, in response to a predetermined rate of change of the fluid pressure in the common outlet line, to cause the selected valve to open or close.
 2. The fill apparatus of claim 1, comprising a fluid compressor and a common inlet line, the fluid compressor communicating with the common inlet line and the common inlet line communicating with the first and second fluid storage bank.
 3. The fill apparatus of claim 2, comprising a control valve operable to selectively control the flow of a fluid from the compressor to the common inlet line.
 4. The fill apparatus of claim 3, comprising a vessel filling station communicating with the common outlet line.
 5. The fill apparatus of claim 4, wherein the compressor communicates with the common outlet line so that the compressor is operable to transmit fluid directly to the vessel filling station.
 6. The fill apparatus of claim 1, comprising a vessel filling station communicating with the common outlet line.
 7. The fill apparatus of claim 6, comprising a fluid compressor and a common inlet line, the fluid compressor communicating with the common inlet line and the common inlet line communicating with the first and second fluid storage bank.
 8. The fill apparatus of claim 7, wherein the compressor communicates with the common outlet line so that the compressor is operable to transmit fluid directly to the vessel filling station.
 9. A fill apparatus for a fluid holding vessels comprising: a fluid conduit; a first and a second valve, each valve communicating with the fluid conduit and each having an inlet port; a pressure measuring device operable to measure a rate of change of a fluid pressure in the fluid conduit; and a programmable logic controller in electronic communication with the first and second valve and the pressure measuring device and operating to transmit a control signal to at least one of the first or second valves in response to a predetermined rate of change of the fluid pressure in the fluid conduit, to cause the selected valve to open or close.
 10. The fill apparatus of claim 9, wherein the first and the second valve comprise solenoid controlled valves.
 11. The fill apparatus of claim 9, comprising a vessel filling station communicating with the fluid conduit.
 12. The fill apparatus of claim 9, further comprising: a housing, the fluid conduit and the first and second valves being positioned on the housing; and a second fluid conduit positioned on the housing.
 13. The fill apparatus of claim 12, comprising a first fluid storage bank having an outlet communicating with the inlet port of the first valve, and a second fluid storage bank having an outlet communicating with the inlet port of the second valve.
 14. The fill apparatus of claim 12, comprising a fluid compressor communicating with the second fluid conduit.
 15. The fill apparatus of claim 12, further comprising a control valve operable to selectively open to allow the flow of a fluid into the second fluid conduit.
 16. The fill apparatus of claim 13, wherein each bank further comprises an inlet in communication with the second fluid conduit.
 17. The fill apparatus of claim 15, comprising a fluid compressor communicating with the control valve.
 18. A method of filling a fluid holding vessel comprising: providing a fill apparatus including a fluid conduit, a first and a second valve, each valve communicating with the fluid conduit and each having an inlet port, a pressure measuring device operable to measure a rate of change of a fluid pressure in the fluid conduit; and a programmable logic controller in electronic communication with the first and second valve and tie pressure measuring device and operating to transmit a control signal to at least one of the first or second valves in response to a predetermined rate of change of the fluid pressure in the fluid conduit; providing a first fluid storage bank having an outlet communicating with the inlet port of the first valve, and a second fluid storage bank having an outlet communicating with the inlet port of the second valve; providing a vessel filling port communicating with the fluid conduit; providing a fluid holding vessel removably engaging and communicating with the vessel filling port so that an interior of the vessel is in communication with the fluid conduit; transmitting a first control signal from the programmable logic controller to the first valve causing the valve to open and a fluid to flow from the first storage bank to the vessel filling port; transmitting a second control signal from the programmable logic controller to the first valve causing the valve to close when the rate of change of a fluid pressure in the fluid conduit has reached a predetermined rate; transmitting a third control signal, after the second control signal, from the programmable logic controller to the second valve causing the valve to open and a fluid to flow from the second fluid storage bank to the vessel filling port.
 19. The method of claim 18, further comprising: providing a fluid compressor in electronic communication with the programmable logic controller and communicating with the fluid conduit so that the compressor is operable to transmit a fluid directly to the vessel filling port; and transmitting a control signal from the programmable logic controller to the compressor causing fluid to flow from the compressor to the vessel filling port.
 20. The method of claim 19, comprising transmitting a control signal from the programmable logic controller to the compressor causing fluid to flow from the compressor to the vessel filling port when the rate of change of a fluid pressure in the conduit has reached a predetermined rate and each bank has been discharged. 